JPS6140164B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a lightweight plate-like synthetic material made of a synthetic resin foam whose surface is reinforced with a synthetic resin film.

Conventionally, various lightweight plate materials made of synthetic resin foam reinforced with reinforcing materials have been proposed.Since foams often have low surface strength and poor weather resistance, in order to improve this point, synthetic resin on the surface is used. Lamination of films is practiced.

Lamination of synthetic resin films is done by foaming a foamable synthetic resin between the synthetic resin films, but air remains between the foam and the synthetic resin film, forming bubbles and causing the adhesion between them. The drawbacks were that the strength was low and the surface had ridges and poor smoothness.

In view of the above-mentioned drawbacks, the present invention is a lightweight plate-like material with a smooth surface, in which a synthetic resin film and a foam are firmly adhered, and which has excellent impact resistance and compressive strength, and is also easy to process. It was developed with the aim of providing a method that can easily and efficiently manufacture superior structural materials, and its gist is that it has an inlet and an outlet, and that at least the upper and lower surfaces of the passageway are A synthetic resin film and a highly immersible reinforcing material are fed along the endless belt into a molding path made up of an endless belt, with the film facing the belt, and then a curable resin that hardens in a short time is applied over the endless belt. A laminate impregnated with a liquid is supplied, and a composite material is supplied thereon with a foamed curable resin liquid that foams and hardens in a short time as a reinforcing material, and the composite material is passed through a molding passage. , a method for manufacturing a lightweight plate-like material, characterized in that the foamed curable resin liquid is foamed and hardened in the molding passage, and the curable resin liquid is also hardened.

The molding passage used in the present invention has an inlet and an outlet, and is surrounded by walls so that its cross-sectional shape is plate-shaped, and at least the upper surface of the passage And the lower surface is made up of an endless belt. It is preferable that the endless belt constituting the lower surface is provided so as to protrude beyond the entrance, and it is preferable that a material such as a reinforcing material is placed on this protrusion and fed into the passage. Since foaming and curing of the foamed curable resin liquid and hardening of the curable resin liquid take place in the passage, a heating device for promoting the foaming and curing of the resin liquid and a heating device for promoting the foaming and curing of the resin liquid are also installed in the passage. A cooling device for cooling may be provided.

The foamed curable resin liquid used in the present invention refers to a synthetic resin liquid that can be foamed and cured in a short time, such as polyurethane, unsaturated polyester,
Resin liquids such as phenolic resins, urea resins, melamine resins, and epoxy resins are used after being imparted with foamability and curability. Among these resin liquids, hard polyurethane is particularly suitable.

Further, the curable resin used in the present invention refers to a synthetic resin that can be cured in a short time, and may have foaming properties, such as the resin liquid used in the foamed curable resin liquid and this resin. Examples include resin liquids that have been given foaming properties.

The reinforcing material used in the present invention refers to any material capable of reinforcing the foam, such as honeycomb materials such as paper honeycomb, resin-coated paper honeycomb, plastic honeycomb, asbestos honeycomb, aluminum foil honeycomb, glass roving, glass chop, Examples include glass fibers such as glass roving cloth, glass pine, glass paper, continuous strand pine, chopped strand pine, natural fibers, and synthetic fibers.

In addition, the highly impregnable reinforcing material used in the present invention is a reinforcing material that can be easily impregnated with the curable resin, and
Examples include glass fibers, synthetic fibers, natural fibers, etc. Non-woven fabrics are preferred, and non-woven fabrics made of glass fibers such as glass paper, small strand mat, and chopped strand mat are particularly preferred because of their high strength. Suitably used. The thickness of the highly impregnable reinforcing material is not particularly limited, but it is preferably 0.05 to 5 mm, and 0.1
-2 mm is more preferable. The synthetic resin film used in the present invention is a film made of synthetic resin, and any film can be used, but polyfluorinated vinyl film and polymethyl methacrylate film, which have excellent weather resistance, are preferably used.

Note that the foamed curable resin liquid and curable resin liquid used in the present invention contain calcium carbonate, talc,
Inorganic fillers such as aluminum hydroxide, lightweight aggregates such as shirasu balloons, barlite, glass balloons, silica sand, etc. may be mixed.

In the present invention, the synthetic resin film and highly impregnating resin liquid are supplied along the endless belt so that the film faces the belt side, and the curable resin liquid that hardens in a short time is supplied from above. At the same time, a composite material having a foamed curable resin liquid that foams and hardens in a short time is supplied onto the reinforcing material, and the foamed laminate is supplied while passing through a molding passage. A lightweight plate-like material is manufactured by foaming and curing the curable resin liquid and curing the curable resin liquid.

FIG. 1 is an explanatory diagram showing an embodiment of the method of the present invention, in which 1 is a molding passage; 11 is a molding passage 1;
The endless belt 13 constitutes the upper surface, and the endless belt 12, 14 also constitutes the lower surface.
are guide rolls of the endless belts 11 and 13, respectively. However, endless belt 11,
The direction in which the endless belt 13 rotates is the direction indicated by the arrow, and the point where the endless belt enters the forming path 1 is the inlet, and the point where it exits is the outlet. The lower endless belt 13 is provided to protrude from the entrance of the molding passage 1, so that it is convenient to place the molding material thereon. In addition, 3 and 3' are glass rovings that are aligned in the direction of movement shown by the arrow and are arranged horizontally at regular intervals.
1, 31' is a winding body of glass roving, 32,
32', 33, 33', and 34 are roving guide rolls, respectively. In addition, 4, 4' are glass paper, 41, 41' are rolls thereof, 42, 4
2' is a guide roll. 5, 5' are polyfluorinated vinyl films, and 51, 51' are the rolls 5 thereof.
2, 52' is a guide roll. Further, 2 is a plate-shaped honeycomb material, 21 is its guide roller,
The honeycomb material 2 is supplied diagonally from above to the forming passage 1, and initially floats in a lifted state from the pulled-out bottom endless belt 13, but as it progresses, the degree of floating gradually decreases, and the forming process is completed. When the honeycomb material 2 comes close to the entrance of the passageway 1, it is no longer lifted and the honeycomb material 2 is supported by the endless belt 13.

The honeycomb material and the glass roving 3 are laminated on an endless belt 13, and a foamed curable resin liquid is supplied from above from a resin liquid discharge device 61 to form a composite material. Further, the polyfluorinated vinyl film 5 and the glass paper 4 are laminated on the endless belt 11 with the film 5 facing the belt side, and the polyfluorinated vinyl film 5' and the glass paper 4' are laminated on the endless belt 13 so that the film 5' are stacked so that they are on the belt side, and a curable resin liquid is supplied from the resin liquid discharge devices 62 and 63, and the curable resin liquid is impregnated into the glass papers 4 and 4' to form a laminate. The composite material and the laminate are then supplied to the molding passage 1, where the foamed curable resin liquid is foamed and expanded, and the foamed resin is applied to the voids of the honeycomb structure and the glass roving on the bottom surface. At the same time, the foaming pressure penetrates into the glass roving on the upper surface, foams, and then hardens. At the same time, it adheres to the hardening resin liquid resin in the molding passage 1, and the synthetic resin foam becomes a polyvinyl fluoride film. 5, 5' and reinforced with the honeycomb material 2, glass rovings 3, 3' and glass paper 4, 4', from the exit of the forming passage 1 to a drawing device (not shown). It is picked up and cut into regular lengths.

FIG. 2 is a cross-sectional view showing a plate-like material manufactured by the method of the present invention explained in FIG.
0 and 30' are polyfluorinated vinyl films that are integrally laminated on the outer surfaces of foam layers 30 and 30' that are reinforced with glass rovings and glass paper that are integrally provided on the upper or lower surface of the Ninicum material 2. .

The method for manufacturing the lightweight plate material of the present invention is as described above, and the foamed curable resin liquid is supplied to the laminate of the highly impregnable reinforcing material laminated to the synthetic resin film and impregnated with the curable resin liquid on the belt. Since the composite material is layered on the cured composite material and foamed and cured in the molding channel, the synthetic resin film is completely bonded to the hardening resin without creating any bubbles due to residual air between the synthetic resin film and the foam. When bonded together, lightweight synthetic materials with high adhesive strength and smooth surfaces can be manufactured. In addition, the surface of the obtained synthetic material is reinforced with a synthetic resin film, and has high surface strength and excellent weather resistance. Furthermore, the surface layer is reinforced with a highly impregnable reinforcing material, and the inside is a foam reinforced with a reinforcing material, so it has excellent impact resistance, mechanical strength, rigidity, workability, etc., and is lightweight, making it ideal for residential use. It is possible to continuously produce plate-shaped materials suitable for use in insulation wall materials, floor materials, bench or balcony materials, truck loading materials, land or sea container materials, core materials for FRP ships, etc.

[Brief explanation of the drawing]

FIG. 1 is an explanatory view showing an example of the method of the present invention, and FIG. 2 is a sectional view showing an example of a plate-shaped material manufactured by the method of the present invention. 1...Molding passage, 11, 13...Endless belt, 2...Nicum material, 3,3'...Glass roving, 4,4'...Glass paper, 5,
5'...Polyfluorinated vinyl film, 6...Synthetic resin foam, 61, 62, 63...Resin liquid discharge device, 7...Lightweight plate material, 30, 30'...Reinforced with glass roving and glass paper foamed layer, 50, 50'...polyfluorinated vinyl film.

Claims (1)

[Claims] 1 A synthetic resin film and a highly impregnable reinforcing material are placed along the endless belt in a molding passageway having an inlet and an outlet, and at least the upper and lower surfaces of the passageway are constituted by an endless belt. The film is supplied so that it is on the belt side, and a curable resin liquid that hardens in a short time is supplied from above to supply the impregnated laminate, and the reinforcing material is foamed and hardened in a short time on top of it. Supplying a composite material supplied with a foamed curable resin liquid and causing it to pass through a molding passage, foaming and hardening the foamed curable resin liquid within the molding passage, and curing the curable resin liquid. A method for producing a lightweight plate-like material characterized by: 2. The manufacturing method according to claim 1, wherein the foamed curable resin liquid is a hard polyurethane resin liquid. 3. The manufacturing method according to claim 1, wherein the curable resin liquid is a foamed curable resin liquid. 4. The manufacturing method according to claim 1, wherein the reinforcing material is a honeycomb material. 5. The manufacturing method according to claim 1, wherein the synthetic resin film is a polyfluorinated vinyl film. 6. The manufacturing method according to claim 1, wherein the synthetic resin film is a polymethyl methacrylate film. 7. The manufacturing method according to claim 1, wherein the highly impregnable reinforcing material is a nonwoven fabric. 8. The manufacturing method according to any one of claims 1 to 7, wherein the highly impregnable reinforcing material is glass fiber.